Method for partially coating complex components with catalytically active components

Abstract

A method for partially coating a shaped body, the surface of which comprises an area to be coated and an area to be left clear, wherein with the method a protective layer is applied to the area to be left clear, a layer comprising a fluid phase is applied to the surface, and the coated shaped body is heated to a temperature at which the protective layer is removed residue-free by pyrolysis.

The invention claimed is: 
     
       1. A method for partially coating a shaped body, the surface of which comprises an area to be coated and an area to be left clear, comprising the steps of:
 a) selectively applying a protective layer to the area to be left clear; 
 b) applying a coating to the surface, wherein the coating comprises a washcoat suspension; and 
 c) heating the coated shaped body to a temperature at which the protective layer is pyrolytically removed residue-free and the coating on the protective layer is delaminated, 
 wherein the shaped body is a metal or ceramic catalyst body or heat exchanger. 
 
     
     
       2. The method of  claim 1 , wherein the coating is a curable coating. 
     
     
       3. The method of  claim 1 , wherein the protective layer is applied to the area to be left clear by spraying, brushing, dipping or rolling. 
     
     
       4. The method of  claim 1 , wherein the protective layer comprises a lacquer, a resin, an adhesive, or a polymer. 
     
     
       5. The method of  claim 4 , wherein the polymer comprises polyethylene glycol, polypropylene glycol, polyacrylate, poly(meth)acrylate, polybutyrate, polyvinyl acetate, polyvinyl alcohol, polyolefin, polyurethane or polyethylene vinyl acetate. 
     
     
       6. The method of  claim 4 , wherein the resin comprises phenol-formaldehyde resin, epoxide resin, melamine-formaldehyde resin or acrylic resin lacquer. 
     
     
       7. The method of  claim 1 , wherein the protective layer is dried after application for ten seconds to three hours. 
     
     
       8. The method of  claim 7 , wherein the protective layer is dried after application for five minutes to 60 minutes. 
     
     
       9. The method of  claim 8 , wherein the protective layer is dried after application for five minutes to ten minutes. 
     
     
       10. The method of  claim 1 , wherein the washcoat suspension is dried and calcined after the application. 
     
     
       11. The method of  claim 10 , wherein the washcoat suspension is dried at a temperature of between 80 and 120° C. 
     
     
       12. The method of  claim 11 , wherein the washcoat suspension is calcined at temperatures of 200 to 600° C. 
     
     
       13. The method of  claim 10 , wherein the washcoat suspension is calcined at temperatures of 200 to 600° C. 
     
     
       14. The method of  claim 1 , wherein the shaped body is shaken after the pyrolysis. 
     
     
       15. The method of  claim 1 , wherein the area of the surface to which the protective layer has been applied is swept with a brush or exposed to a jet of compressed air after the pyrolysis. 
     
     
       16. The method of  claim 1 , wherein the area to be left clear is provided with an imprint or with a barcode. 
     
     
       17. The method of  claim 1 , wherein the shaped body represents a foam structure, a honeycomb body or a micro heat exchanger. 
     
     
       18. The method of  claim 1  wherein
 the shaped body is a metal or ceramic catalyst body or heat exchanger, and wherein the protective layer is applied to the area of the surface to be left clear by spraying, brushing, dipping, or rolling. 
 
     
     
       19. The method of  claim 18 , wherein the coating is a curable coating. 
     
     
       20. The method of  claim 18 , wherein the protective layer comprises a lacquer, a resin, an adhesive, or a polymer. 
     
     
       21. The method of  claim 20 , wherein the polymer comprises polyethylene glycol, polypropylene glycol, polyacrylate, poly(meth)acrylate, polybutyrate, polyvinyl acetate, polyvinyl alcohol, polyolefin, polyurethane or polyethylene vinyl acetate. 
     
     
       22. The method of  claim 20 , wherein the resin comprises phenol-formaldehyde resin, epoxide resin, melamine-formaldehyde resin or acrylic resin lacquer. 
     
     
       23. The method of  claim 18 , wherein the protective layer is dried after application for ten seconds to three hours. 
     
     
       24. The method of  claim 23 , wherein the protective layer is dried after application for five minutes to 60 minutes. 
     
     
       25. The method of  claim 24 , wherein the protective layer is dried after application for five minutes to ten minutes. 
     
     
       26. The method of  claim 18 , wherein the washcoat suspension is dried and calcined after the application. 
     
     
       27. The method of  claim 26 , wherein the washcoat suspension is dried at a temperature of between 80 and 120° C. 
     
     
       28. The method of  claim 26 , wherein the washcoat suspension is calcined at temperatures of 200 to 600° C. 
     
     
       29. The method of  claim 18 , wherein the shaped body is shaken after the pyrolysis. 
     
     
       30. The method of  claim 18 , wherein the area of the surface to which the protective layer has been applied is swept with a brush or exposed to a jet of compressed air after the pyrolysis. 
     
     
       31. The method of  claim 18 , wherein the area to be left clear is provided with an imprint or with a barcode. 
     
     
       32. The method of  claim 18 , wherein the shaped body represents a foam structure, a honeycomb body or a micro heat exchanger.